Bolt thread catalog for GS500 (April 17, 2012)

[Zwerski]

BOLT THREAD SIZES:
Carb bowl screws - 2009 - M4x0.7x10mm
Top diaphragm cover - 2009 - M5x0.8x12mm
Float bowl - 89-00 - M5x0.8x12mm
Fork brace - M6x1.0x14mm
Headlight bracket (to upper forks, GS500E) - M6x1.0x14mm
Air box - M6x1.0x12mm
Rectifier (attachment to battery box) - M6x1.0x10mm
Chain guard - M6x1.0x10mm
Fairing mounts rear (GS500E) - M6x1.0x10mm
Battery box - M6x1.0x20mm
Tank bracket (to frame, GS500E) - M8x1.25x40mm
Headlight bucket mount (GS500E) - M8x1.25x30mm
Headlight set screws (GS500E) - M5x0.8x10mm

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Each time I disassemble a new part of my bike for various maintenance needs, I have been replacing the rusty hardware with new stainless button-head Allen cap bolts. Sometimes, the fasteners are not there due to the PO having monkeyed with some aspect of the bike and not re-fastening the part.

An example: this weekend, I performed the R6 shock swap, and found that my air box was not bolted to the bike. Since I had already replaced the rusty chromed headlight bracket mount bolts with stainless hardware, I had those to use for replacements to the missing air box bolts.

My question is this: is there a resource that lists all of the bolt (and nut) thread sizes for the fastening points on our bikes? If there is not, I propose one can be started. It would make getting replacements easier, especially when the original is not available. I would like to order some hardware, but often need to know the thread sizes and bolt lengths.The walk-up place near me also needs either one of what you're looking for or the size and thread pitch.

Whaddya think?

[Tombstones81]

yes that is a Really good idea.

and no I am yet to come across a giant list of replacement parts like bolts, nuts, etc etc

[dropitlow88]

That could be an extensive list lol. I usually just take one with me. Makes it easy for me, nothing to remember lol.

[bombsquad83]

Some industrious person on the boards should do this research and buy like 100 of each of the common bolts on our bike in stainless, then make sets to sell at a small profit for each set.   If I didn't have a wife and a budget, I'd be all over it.

[dropitlow88]

Some industrious person on the boards should do this research and buy like 100 of each of the common bolts on our bike in stainless, then make sets to sell at a small profit for each set.   If I didn't have a wife and a budget, I'd be all over it.

that sounds like a full time job!

[Worm]

I just wanna know what the size is for the ones holding the float bowls on. I thought I had the size of 5mm-.8 x 12mm, but turns out that size is not correct. It looked like they may fit the covers on top of the carbs but I didn't remove those to check.

[bombsquad83]

M5x0.8x12mm is the correct size for the float bowls in the '89-'00 models.  Not sure about the newer models.

[Worm]

Well they are definitely smaller diameter and shorter on the newer carbs. I was kind of disappointed because I had the bag of SS socket caps to replace them with!

[slipperymongoose]

That's alot of bolts.

[Zwerski]

Some industrious person on the boards should do this research and buy like 100 of each of the common bolts on our bike in stainless, then make sets to sell at a small profit for each set.   If I didn't have a wife and a budget, I'd be all over it.

Or, at least, once someone on the forum finds out what size is what, it can be logged here somewhere.

I know that the air box bolts, "E" headlight bracket mounts and lower fork brace bolts are all the same size and pitch, whatever that may be.

M5x0.8x12mm is the correct size for the float bowls in the '89-'00 models.  Not sure about the newer models.

Perfect. Our first entry.

Float bowl - 89-00 - M5x0.8x12mm

[bombsquad83]

Cool.  Some of these sizes are already posted on the wiki, so check that out.  I'll be sure to post up to this thread whenever I figure out another bolt's size and pitch.

[twinrat]

2009 carb bowl screws are 4x0.7x10mm .top diaphram cover screws are 5x0.8x12mm

[Worm]

Well I'll be picking up a bag of the M4-.7 x 10mm in stainless in the near future.

[Zwerski]

Whelp, I ordered a thread reader which arrived in the mail yesterday, and commenced measuring all the non-load-bearing, low-shear fasteners on my 1997 E. I updated the fastener stats in the initial post, and have ordered fasteners - stainless button head bolts, nuts and washers - from Bolt Depot. I purchased double what I need, plus more extra (a buddy nearby wants to do a similar fastener replacement project as I) and both sets shipped to me cost $27. Another supplier option is McMaster-Carr, but they require box purchases - 25/50/100 - while Bolt Depot will sell singles of anything they offer.

If you plan to do this same project, Google "stainless thread galling" to avoid seizing stainless fasteners into your bike.

[Worm]

Check out your local Fastenal or on their website for stainless fasteners. I got 8 float bowl screws plus the 2 shorter ones that are holding a bracket to the bottom of one of the float bowls in stainless button socket caps and 2 flat socket caps to replace the screws in the cover over the front sprocket for $3.63!!     Cheapest I found at a hardware store was $1.20 per screw!

[DoD#i]

Started years ago on the wiki, as I recall. Feel free to extend, add to, make notes about year-to year differences, etc. - It is useful to have.

http://wiki.gstwins.com/index.php?n=Restoration.BoltSizes

[bombsquad83]

Nice job. 

I didn't have a local Fastenal that had the carb bowl screws in stock.  In that case it would have been a little cheaper through Bolt Depot.  Good to know. 

This info can be cross-checked and added to the wiki somehow (not sure how to update it?).  The current wiki doesn't have all the bolts that you checked.

[Zwerski]

Cool! The Wiki needs a password to be updated. I'm not the one with access to it.

[DoD#i]

Last I recall, your board (ie, how you get on here) username/password worked. Dunno if that's still true (the gallery/wall of fame was all screwed up last time I tried to visit it.)

[fakejimmymorgan]

air filter m5x10mm air box m6x16mm frame petcock m6x16mm